Open molding is the method used in the polymer-matrix composites industry to make thermoset composite products. This article discusses the advantages, disadvantages, and applications of the open molding. It describes the various process of the open molding, such as hand lay-up process and spray-up process. Workmanship for hand lay-up and spray-up processes is reviewed. The article provides information on the matrix-resin materials used for open molding, including unsaturated polyester resins, epoxy vinyl ester resins, and reinforcements. It explains the component design and short- and long-term properties of a fiber reinforced composite laminate depending on material selection and workmanship. The article also presents the basic design guidelines for open molding.

This article describes the chemistry of phenolic resins and reviews their characteristics and properties for various composites fabrication processes. The fabrication processes include solution/hot-melt process, pultrusion, vacuum infusion, filament winding, sheet molding, and hand lay-up. The article illustrates the manufacturing process of phenolic honeycomb and provides information on the applications of phenolic composites.

The prepreg hand lay-up process is a versatile, reliable, cost-effective, and high quality process for fabricating large or small components. This article discusses the technique characteristics and applications of the process. It describes the stages involved in the process of lay-up, namely, lay-up definition, ply-kit cutting, layup, debulking, and preparation for curing. The article concludes with a discussion on the component properties and design guidelines of the prepreg hand lay-up process.

This article presents the basic guidelines considered in designing a composite structure, and the basic definitions of terms that apply to composites. It describes the analysis of a composite laminate based on stress-strain relationships, stress-strain load relationships, general load displacement case, and general load case solution. Factors affecting the composite materials properties and allowables of fiber-reinforced polymers are reviewed. The article discusses the process considerations for mold design, such as master model, metal tooling, composite tooling, and tool care. It explains the resin selection in designing the composite for use in a particular application. The article illustrates the various methods that are used to process a composite component, namely, wet lay-up, autoclave, resin transfer molding, and vacuum-assisted resin transfer molding. It provides a discussion on electromagnetic interference shielding, electrostatic discharge protection, metal plating, fire resistance, and corrosion resistance on composite materials.

This article describes the types of fabrics and preforms used in the manufacture of advanced composites and related selection, design, manufacturing, and performance considerations. The types of fabrics and preforms include unidirectional and two-directional fabrics; multidirectionally reinforced fabrics; hybrid fabrics; woven fabric prepregs; unidirectional and multidirectional tape prepregs; and the prepreg tow. The article discusses three major categories of tape manufacturing processes, namely, the hand lay-up, machine-cut patterns that are laid up by hand, and the automatic machine lay-up. It provides a description of the two classes of prepregs. These include those that are suitable for high-performance applications and suitable for lower-performance molding compounds.

Composite tooling is the making of tools from composite materials. This article focuses on wet lay-up methods and techniques that are used to fabricate prepreg tooling. It discusses the advantages and disadvantages of composite tools. The article describes the process considerations for composite tool design, such as master model or pattern design selection, fiber and fabric selection, resins, and surface coat and ply. Various tool laminate construction techniques, such as curing and demolding, and cutting and trimming, are reviewed. The article also describes the substructure design for the construction of tool laminates.

Wet lay-up using hand or spray techniques is one of the simplest methods of combining a fiber reinforcement with a solidifying resin to form a composite structure. This article describes several wet lay-up processes - including contact molding, spray molding, vacuum bag molding, and autoclave molding - suited for making parts on open-faced molds using polyester and vinyl ester resins. The article also provides information on mechanically assisted lay-up which can be automated to alleviate some of the manual work.